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Maintenance Program Jenbacher

The document provides a maintenance schedule for a Jenbacher gas engine with intervals for inspection and maintenance tasks. It lists tasks to be completed daily, weekly, monthly, yearly, and every 2,000 to 30,000 operating hours, including checking oil levels, filters, batteries, coolers, and heat exchangers. The schedule also notes that plant-specific maintenance operations are incorporated according to engine type and version.

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Helder Pinto
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100% found this document useful (2 votes)
2K views

Maintenance Program Jenbacher

The document provides a maintenance schedule for a Jenbacher gas engine with intervals for inspection and maintenance tasks. It lists tasks to be completed daily, weekly, monthly, yearly, and every 2,000 to 30,000 operating hours, including checking oil levels, filters, batteries, coolers, and heat exchangers. The schedule also notes that plant-specific maintenance operations are incorporated according to engine type and version.

Uploaded by

Helder Pinto
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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back to Menu J612-620

Jenbacher C
Documentation Maintenance schedule

Intervals independent of the number of operating hours


Inspection task Number/ Interval Note
section
Carry out daily visual inspection of the
Daily inspection round I 9003 0 daily
unit.
Operating data log --- daily Log the operating data daily.
If the manometer at the pocket filter
shows negative pressure >10 mbar (1
Intake air filter-Engine IW 8041 A6 daily kPa), the filter needs to be replaced, (or
else replace them after 2,000 operating
hours at the latest).
Visual inspection of the overvoltage
Overvoltage suppressor IW 8048 A0 daily
deflectors.
Transmission IW 8071 A0 weekly Check oil level.
The result of the ignition voltage check to
Check ignition voltage/spark IW 0309 M0 weekly be carried out weekly, serves as the
plug TA 1400-0104 < 250 oh indicator for the actual service life of the
spark plug.
IW 0101 M6
The results from the engine lubricating oil
TA 1000-0099A first time after
Lubricating oil analyses are decisive for the actual oil
TA 1000-0099B 150 oh
change periods.
TA 1000-0099C
Check oil level and Check oil pressure.
Pre-chamber gas
IW 8046 0 weekly Check operation of float condensate
compressor
discharge unit.
Check the acid level.
Battery TA 1000-0050 once in a month Check if the pole binders are properly
secured.
Check air filter for pollution.
Air filter in switch cabinet --- once in a month
If necessary, clean or replace.
Check switch cabinet cooler for clogging
Switch cabinet cooler --- once in a year and, if necessary, clean using
compressed air.
once a year or in
Smoke warning unit and gas accordance with Check
---
warning unit official (observe the official regulations).
regulations
Heat exchangers with a water
2,000 oh
temperature >100°C are classified as
installations requiring special supervision.
Heat Before commissioning - and subsequently
Heat exchanger exhaust gas exchangers
I 0103 6 at regular intervals - these installations
/ water >100°C water are legally subjected to inspections by
temp. in acc. certified inspection agencies (e.g.
with official operational safety regulations, steam
regulations boiler regulations, etc.).

Tip: The maintenance operations highlighted in green in the maintenance plan are plant-specific and are
incorporated into the customer-specific maintenance plan according to engine type and version.

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 1 / 11
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Jenbacher C
Documentation Maintenance schedule

Intervals independent of the number of operating hours


Inspection task Number/ Interval Note
section
TA 1000-0200
Cooling water TA 1000-0201 once in a year Concentration inspection
TA 1000-0204
30,000 oh
after having
W 8080 A0 completed the Cooling water exchange
overhaul
activities
The overriding factor for the actual active-
carbon interchange intervals are the
Activated carbon adsorber W 8074 A0 --
results of the active carbon mass increase
measurements.
Condensate removal in fuel-
gas system
(if part of GE Jenbacher’s
scope of supply) IW 8090 A0 2,000 oh Check for gas leaks
at least 4 times
Automatic condensate a year
removal
Manual condensate drains if required Condensate drain
2,000 oh at least
once a quarter
All pipes and components
8,000 oh at
carrying fuel gas and IW 8049 0 Leak test
least once a
mixtures
year for natural
gas only
30,000 Oh
Compressed air starter W 8032 M0 or once every 4 Overhaul
years
30.000 oh
Crankshaft main bearing/ at 30.000 operating hours or 4,000 engine
W 8050 M6 (4,000 engine
thrust bearing starts maximum - replace
starts)
Battery in DIANE module --- every two years Replace
Storage battery at battery
--- every five years Replace
charger
Emission measurement according to official guidelines.
Comment: If the emission levels listed in the specification
Manual condensate drains ---
are exceeded, inspect and, if required, clean the
combustion chambers (W 8056 M0).

Proper maintenance according to the maintenance schedule is a condition for honouring any claims
under warranty.
The risk assessment to be performed by the plant operator and the official and quasi-official safety rules
and laws may give rise to acceptance tests, inspections and maintenance operations which are not
included in the Maintenance Plan. It is the operator’s responsibility to implement and enforce these
additional measures.

The maintenance intervals have been determined on the basis of experience of maintaining average
operating levels while fully complying with the manufacturer’s operating and maintenance instructions. In

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 2 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

individual cases, the operating conditions and other factors relating to wear may affect the actual amount
of maintenance required. The manufacturer therefore reserves the right to specify different maintenance
intervals where appropriate.

After the „Overhaul“ 60,000 operating hours, the maintenance work to be carried out is repeated at the
same interval periods.

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 3 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly


Maintenance task/ Number Maintenance task/
Interval ref. nr.

Inspection task Inspection task

< 100
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
- Maintenance after first start-up W 1000 6
2 Valve clearance W 0400 M6
2 Ignition system W 0303 M0
2 Inspection I 0103 6
2 Table cooler W 8065 A0
2 Intake air filter (ROLF) - Engine r IW 8040 A6
2 Crankcase vent W 0509 M6
2 Turbocharger (PBST - TCR) W 8025 M0
2 Turbocharger (PBST - NR) W 8025 M6
2/8 Leak test IW 8049 0
2/4/8 Transmission IW 8071 A0
2/6/
10/30 Pre-chamber gas compressor IW 8046 0
2/20/
30 Regulating rods/Throttle valve/Actuator W 0200 M6
2/30/
60 Gas train W 8045 A6
4/20 Coupling housing on elastic bearings W 8079 A6
4 Oil filter insert (J 620) W 8038 M6
6 Oil filter insert (J 612/J 616) W 8038 M6
Prechamber/Prechamber gas valve/Spark
6/10
plug sleeve
W 0501 M6
10 Crankshaft thrust bearing
(with transmission only)
W 8060 M6
10 Starter W 8032 M0
10 Torsion vibration damper
(with J 612 ≥22bar only)
W 0601 M0
10/30 Engine coolant pump W 0203 A6
20 Turbocharger (ABB_A-135_A-135) W 8026 M6
20 Turbocharger (ABB_TPS52E_TPS57E) W 8024 M6
20 Jenbacher-switch cabinets W 8031 A0
20 Torsion vibration damper W 0601 M0
20 Mixture bypass valve W 0802 M6
30 Compressed air starter W 8032 M0
30 Piston/Piston cooling W 8047 M6
30 Cylinder liner W 8049 M6
30 Gas quantity controller W 0705 M0
30 Engine oil pump W 8046 M6
30 Con rod/Con rod bearing W 8048 M0
30 Crankshaft main bearing/thrust bearing W 8050 M6
ZK Camshaft/Control parts
30/60
W 8052 M0
60 Plate-type heat exchanger W 8043 A0
60 Pre-lubricating pump W 8054 M0
60 Overhaul W 2100 M0

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 4 / 11
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Jenbacher C
Documentation Maintenance schedule

ZK Exhaust gas manifold/Isolation W 8051 M0


- Generator (Leroy Somer_LSA47-54) W 8032 A0
- Generator (Stamford_Avk_BR 8 /
W 8030 A0
Dig110_140)
- Elastomer parts W 8034 6
- Cylinder head replacement W 8053 M6 if required

Please note that properly carried out maintenance work is to be acknowledged by


filling in the maintenance protocol.

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 5 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly


Maintenance task/ Number Operating hours
Interval ref. nr.

Inspection task

16000
17000
18000
19000
20000
21000
22000
23000
24000
25000
26000
27000
28000
29000
30000
2 Valve clearance W 0400 M6
2 Ignition system W 0303 M0
2 Inspection I 0103 6
2 Table cooler W 8065 A0
2 Intake air filter (ROLF) - Engine r IW 8040 A6
2 Crankcase vent W 0509 M6
2 Turbocharger (PBST - TCR) W 8025 M0
2 Turbocharger (PBST - NR) W 8025 M6
2/8 Leak test IW 8049 0
2/4/8 Transmission IW 8071 A0
2/6/
10/30 Pre-chamber gas compressor IW 8046 0
2/20/
30 Regulating rods/Throttle valve/Actuator W 0200 M6
2/30/
60 Gas train W 8045 A6
4/20 Coupling housing on elastic bearings W 8079 A6
4 Oil filter insert (J 620) W 8038 M6
6 Oil filter insert (J 612/J 616) W 8038 M6
Prechamber/Prechamber gas valve/Spark
6/10
plug sleeve
W 0501 M6
10 Crankshaft thrust bearing
(with transmission only)
W 8060 M6
10 Starter W 8032 M0
10 Torsion vibration damper
(with J 612 ≥22bar only)
W 0601 M0
10/30 Engine coolant pump W 0203 A6
20 Turbocharger (ABB_A-135_A-135) W 8026 M6
20 Turbocharger (ABB_TPS52E_TPS57E) W 8024 M6
20 Jenbacher-switch cabinets W 8031 A0
20 Torsion vibration damper W 0601 M0
20 Mixture bypass valve W 0802 M6
30 Compressed air starter W 8032 M0
30 Piston/Piston cooling W 8047 M6
30 Cylinder liner W 8049 M6
30 Gas quantity controller W 0705 M0
30 Engine oil pump W 8046 M6
30 Con rod/Con rod bearing W 8048 M0
30 Crankshaft main bearing/thrust bearing W 8050 M6
ZK Camshaft/Control parts
30/60
W 8052 M0
60 Plate-type heat exchanger W 8043 A0
60 Pre-lubricating pump W 8054 M0
60 Overhaul W 2100 M0
ZK Exhaust gas manifold/Isolation W 8051 M0

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 6 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

Generator (Leroy Somer_LSA47-54) W 8032 A0


Generator (Stamford_Avk_BR 8 /
- Dig110_140) W 8030 A0
- Elastomer parts W 8034 6
- Cylinder head replacement W 8053 M6 if required

Please note that properly carried out maintenance work is to be acknowledged by


filling in the maintenance protocol.

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 7 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly


Maintenance task/ Number Operating hours
Interval ref. nr.

Inspection task

31000
32000
33000
34000
35000
36000
37000
38000
39000
40000
41000
42000
43000
44000
45000
2 Valve clearance W 0400 M6
2 Ignition system W 0303 M0
2 Inspection I 0103 6
2 Table cooler W 8065 A0
2 Intake air filter (ROLF) - Engine r IW 8040 A6
2 Crankcase vent W 0509 M6
2 Turbocharger (PBST - TCR) W 8025 M0
2 Turbocharger (PBST - NR) W 8025 M6
2/8 Leak test IW 8049 0
2/4/8 Transmission IW 8071 A0
2/6/
10/30 Pre-chamber gas compressor IW 8046 0
2/20/
30 Regulating rods/Throttle valve/Actuator W 0200 M6
2/30/
60 Gas train W 8045 A6
4/20 Coupling housing on elastic bearings W 8079 A6
4 Oil filter insert (J 620) W 8038 M6
6 Oil filter insert (J 612/J 616) W 8038 M6
Prechamber/Prechamber gas valve/Spark
6/10
plug sleeve
W 0501 M6
10 Crankshaft thrust bearing
(with transmission only)
W 8060 M6
10 Starter W 8032 M0
10 Torsion vibration damper
(with J 612 ≥22bar only)
W 0601 M0
10/30 Engine coolant pump W 0203 A6
20 Turbocharger (ABB_A-135_A-135) W 8026 M6
20 Turbocharger (ABB_TPS52E_TPS57E) W 8024 M6
20 Jenbacher-switch cabinets W 8031 A0
20 Torsion vibration damper W 0601 M0
20 Mixture bypass valve W 0802 M6
30 Compressed air starter W 8032 M0
30 Piston/Piston cooling W 8047 M6
30 Cylinder liner W 8049 M6
30 Gas quantity controller W 0705 M0
30 Engine oil pump W 8046 M6
30 Con rod/Con rod bearing W 8048 M0
30 Crankshaft main bearing/thrust bearing W 8050 M6
ZK
Camshaft/Control parts W 8052 M0
30/60
60 Plate-type heat exchanger W 8043 A0
60 Pre-lubricating pump W 8054 M0
60 Overhaul W 2100 M0
ZK Exhaust gas manifold/Isolation W 8051 M0
Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X
Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 8 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

- Generator (Leroy Somer_LSA47-54) W 8032 A0


Generator (Stamford_Avk_BR 8 /
- Dig110_140) W 8030 A0
- Elastomer parts W 8034 6
- Cylinder head replacement W 8053 M6 if required

Please note that properly carried out maintenance work is to be acknowledged by


filling in the maintenance protocol.

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 9 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly


Maintenance task/ Number Operating hours
Interval ref. nr.

Inspection task

46000
47000
48000
49000
50000
51000
52000
53000
54000
55000
56000
57000
58000
59000
60000
2 Valve clearance W 0400 M6
2 Ignition system W 0303 M0
2 Inspection I 0103 6
2 Table cooler W 8065 A0
2 Intake air filter (ROLF) - Engine r IW 8040 A6
2 Crankcase vent W 0509 M6
2 Turbocharger (PBST - TCR) W 8025 M0
2 Turbocharger (PBST - NR) W 8025 M6
2/8 Leak test IW 8049 0
2/4/8 Transmission IW 8071 A0
2/6/
10/30 Pre-chamber gas compressor IW 8046 0
2/20/
30 Regulating rods/Throttle valve/Actuator W 0200 M6
2/30/
60 Gas train W 8045 A6
4/20 Coupling housing on elastic bearings W 8079 A6
4 Oil filter insert (J 620) W 8038 M6
6 Oil filter insert (J 612/J 616) W 8038 M6
Prechamber/Prechamber gas valve/Spark
6/10
plug sleeve
W 0501 M6
10 Crankshaft thrust bearing
(with transmission only)
W 8060 M6
10 Starter W 8032 M0
10 Torsion vibration damper
(with J 612 ≥22bar only)
W 0601 M0
10/30 Engine coolant pump W 0203 A6
20 Turbocharger (ABB_A-135_A-135) W 8026 M6
20 Turbocharger (ABB_TPS52E_TPS57E) W 8024 M6
20 Jenbacher-switch cabinets W 8031 A0
20 Torsion vibration damper W 0601 M0
20 Mixture bypass valve W 0802 M6
30 Compressed air starter W 8032 M0
30 Piston/Piston cooling W 8047 M6
30 Cylinder liner W 8049 M6
30 Gas quantity controller W 0705 M0
30 Engine oil pump W 8046 M6
30 Con rod/Con rod bearing W 8048 M0
30 Crankshaft main bearing/thrust bearing W 8050 M6
ZK Camshaft/Control parts
30/60
W 8052 M0
60 Plate-type heat exchanger W 8043 A0
60 Pre-lubricating pump W 8054 M0
60 Overhaul W 2100 M0
ZK Exhaust gas manifold/Isolation W 8051 M0

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 10 / 11
back to Menu J612-620
Jenbacher C
Documentation Maintenance schedule

- Generator (Leroy Somer_LSA47-54) W 8032 A0


Generator (Stamford_Avk_BR 8 /
- Dig110_140) W 8030 A0
- Elastomer parts W 8034 6
- Cylinder head replacement W 8053 M6 if required

Please note that properly carried out maintenance work is to be acknowledged by


filling in the maintenance protocol.

Keyword: Standard Unit no.: J XXXX Module no.: XXXXXX X


Module type : J612-620GS Version: FXXX Engine no.: XXXXXX X

Issued: Doku./Bilek Checked: TEM/TET/GSD/VMP (TSD-Mitt. 1747 / 2010) Date: 2011-01


EN WP612- 620_A_EN .doc Index: c Page - No.: 11 / 11

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